Base Scaffold Control Panel

@@ -1,13 +1,12 @@ # Base Scaffold Control Panel -> **Status: DRAFT.** Owned by **Caleb**. Specifications below are drawn from the two board-> designs that implement the panel. Items still marked `🔶 FILL-IN` are values not yet+> **Status: DRAFT.** Owned by **Caleb**. Items marked `🔶 FILL-IN` are values not yet > published. This page is a dependency of the > [Base Scaffold System](https://wiki.adom.inc/adom/base-scaffold-system) main page. -The control panel is the electrical front door of the Base Scaffold System: it carries the scaffold's power and signal interface and provides the connector/disconnect that mates the scaffold to a workcell each time it docks.+The control panel is the electrical front door of the Base Scaffold System: it carries the scaffold's power and signal interface and provides the connect/disconnect that mates the scaffold to a workcell each time it docks. -It is a **two-board pair** that mate at a blade dock — one half stays with the workcell, the other rides on the base scaffold with the customer's project.+It is a two-board pair that mate at a blade dock. One half stays with the workcell, the other rides on the base scaffold with the project.  ## The Pair @@ -30,71 +29,96 @@ The two halves mate coplanar at the blade dock, with the project's molecules, ju  ![Mated control panel assembly](docs/mated-assembly.gif) -## Specifications+## Input power -### Input power+Four independent bench-supply input to the workcell control panel. Every rail is+individually metered at 20-bit precision with **INA228**. -Four independent bench-supply inputs land on the workcell side at a WAGO terminal block-(dual contacts per pole). **Every rail is individually metered at 20-bit precision-(±0.05 %)**, so consumption is visible live throughout a project's life.--| Rail | Rating | Notes |+| Rail | Rating | Description | |---|---|---|-| **PS1** | 0–60 V / 12 A | User-variable — behaves like a bench supply the customer can set |-| **PS2** | 5 V / 10 A | **Switchable** — can be commanded on/off without touching the bench supply |-| **PS3** | spare | Passed straight through to the scaffold |-| **PS4** | 5 V | Powers the panel itself, behind a 6.3 A fuse. Not a project rail. |+| **PS1** | 0–60 V / 12 A | User variable power supply with full control |+| **PS2** | 5 V / 10 A | User enabled static supply. Isolated return may float up to **±2.5 V** from common |+| **PS3** | — | User supply — spare |+| **PS4** | 5 V | Internal 5 V rail | -PS1–PS3 cross the dock to the scaffold on power blades. Each rail's return arrives at the-scaffold **isolated**, and a switched rail's isolated return may float up to **±2.5 V**-from common ground.+All user power supplies may be isolated by removing ground jumpers as indicated on the+scaffold control panel. -**Ground scheme.** Large machine-pin jumper fields bond a **single return-to-ground per-rail** (default: bridged), so each rail's grounding is an explicit, per-project choice-rather than a fixed assumption.+**Ground scheme.** Large machine-pin jumpers bond a single return-to-ground per rail+(default: bridged), so each rail's grounding is an explicit, per-project choice rather than+a fixed assumption.  🔶 **FILL-IN (Caleb):** aggregate power budget for the panel as a whole — the board designs specify per-rail ratings only, not a combined ceiling or simultaneous-load derating. -### I/O available to the project+## I/O available to the project -Everything the project touches lands on the scaffold side, at a **65-contact machine field-(62 medium + 3 large)** — the same contact system used across the base scaffold, so project-wires and panel wires terminate identically.+The user is given full control of the nested **RP2350A**, with **26 available I/O**+([RP2350A Mini](https://hydrogen.adom.inc/caleb/molecules/RP2350A_Mini)) and **USB 2.0**+capable of dual data roles and power delivery. Further, the workcell side of the control+panel offers **two USB-SS ports** capable of 3.0 protocol and power delivery. -| Resource | Provision |-|---|---|-| **Supply rails** | PS1 (sense-tapped), PS2 and PS3, each on its own group of contacts |-| **User MCU I/O** | **26 user I/O lines** from a user-programmable MCU module hosted on the board |-| **USB** | USB-C 2.0 **dual-role**, PD 3.0 A |-| **Grounds / spares** | Rail returns, grounds and spare contacts alongside the above |+**Wireless.** An M.2 Key-E slot carries an **AX210**-class module, providing **Wi-Fi 6E**+across all three bands (2.4 / 5 / 6 GHz) with 160 MHz channel width and 2×2 MIMO for link+rates to ~2.4 Gbps, plus **Bluetooth 5.3** including Low Energy. Wi-Fi runs on PCIe and+Bluetooth on USB.++**Sensing.** The panel carries on-board environmental sensing (temperature, relative+humidity, barometric pressure and air quality) and 6-axis motion sensing (3-axis+accelerometer + 3-axis gyroscope), both available to the project through the workcell+controller. A digital microphone is also fitted for acoustic capture.++### User MCU I/O++26 user I/O reach the machine-contact field. Every line supports digital input/output, PWM+and the MCU's programmable I/O; four are additionally analog-capable.++| Machine contacts | User I/O | Capabilities |+|---|---|---|+| MC31–MC34 | IO29, IO28, IO27, IO26 | Digital I/O, PWM, programmable I/O, **ADC (4 analog channels)**, I²C / SPI / UART alternate functions |+| MC35–MC38 | IO25, IO24, IO23, IO22 | Digital I/O, PWM, programmable I/O, I²C / SPI / UART alternate functions |+| MC39–MC46 | IO19 … IO12 | Digital I/O, PWM, programmable I/O, I²C / SPI / UART alternate functions |+| MC47–MC56 | IO9 … IO0 | Digital I/O, PWM, programmable I/O, I²C / SPI / UART alternate functions |++### USB++| Port | Side | Protocol | Data role | Power |+|---|---|---|---|---|+| **USB-C** | Scaffold (user) | USB 2.0 | **Dual-role** — host or device | Power delivery, 3.0 A; VBUS sourced from PS2 |+| **USB-C** | Workcell | USB 3.0 SuperSpeed | Host | Power delivery, 3.0 A; protected VBUS |+| **USB-A** | Workcell | USB 3.0 SuperSpeed | Host | Power delivery; protected VBUS | -**USB behavior.** In **host** role the board sources VBUS from the switched 5 V rail through-a protected path; in **device** role (for example, plugged into a PC) VBUS sourcing is off-and back-feed into the supply is blocked. VBUS can be brought out to the machine contacts-for the project when wanted.+**USB behavior.** In host role the board sources VBUS from the switched 5 V (PS2) rail+through a protected path; in device role (for example, plugged into a PC) VBUS sourcing is+off and back-feed into the supply is blocked. If VBUS is broken out through machine pins and+CC termination is not satisfied, the CC jumper must be placed. -### Debug and control across the dock+## Debug and control across the dock -The dock also carries the facilities needed to program and control the project's MCU-without opening anything up: **SWD and UART debug**, plus **boot-strap and reset control**-of the user MCU, and low-voltage service rails. A **companion dashboard application**-provides live control and telemetry — meter all four rails, set PS1 like a bench supply,-switch rails, drive the scaffold I/O, and program the user MCU.+The dock carries the facilities needed to program and control the project's MCU without+opening anything up: **SWD and UART debug**, plus boot and reset control of the user MCU,+and low-voltage service rails. A **companion dashboard application** provides live control+and telemetry — meter all four rails, set PS1 like a bench supply, switch rails, drive the+scaffold I/O, and program the user MCU. -> **Note for integrators:** the user MCU's boot and reset lines are **active-low** — both-> must be released (driven high) for the MCU to run the program in its flash.+## Machine contacts -### Workcell-side infrastructure+Project connections land on the scaffold's machine-contact field. Two contact classes are+used; both are solderless press-fit receptacles that accept a machine pin tail, a machine+needle, or a bare solid-core wire. -The workcell half also carries the cell's own connectivity and sensing. These serve the-workcell, not the project directly:+| Property | [Medium contact](https://wiki.adom.inc/adom/machinecontactmedium) | [Large contact](https://wiki.adom.inc/adom/machinecontactlarge) |+|---|---|---|+| **Current rating** | ~**6.4 A** (80 % derated) | ~**20.8 A** (80 % derated) |+| **Mating wire** | 24 AWG solid core (precision-bent, enamel-coated) | 14 AWG solid core (precision-bent, enamel-coated) |+| **Also mates with** | Medium machine pin tail (Ø0.51 mm), medium needle | Large machine pin tail (Ø1.85 mm), large needle |+| **Grid pitch** | 2 mm within a row; rows ≥ 4 mm apart | 8 mm technical; 32 mm as implemented on the base scaffold |+| **Press-fit hole** | Ø0.78 mm plated through-hole, Ø1.30 mm annular pad | Ø2.62 mm plated through-hole, Ø4.40 mm annular pad | -Gigabit Ethernet · Wi-Fi and Bluetooth module slot · CAN FD on daisy-chainable contacts ·-USB-C and USB-A (both protected) · environmental and motion sensing · an indicator LED ring-used for camera-feed verification.+Both ratings are **contact-limited** — the mating pin can carry more, so the contact sets+the figure — and are quoted at 80 % derating for margin. -### Physical+## Physical  | Item | Value | |---|---|@@ -105,7 +129,7 @@ used for camera-feed verification. 🔶 **FILL-IN (Caleb + James/Luke):** mass of each half, and the mounting location and orientation of the panel on the base scaffold frame. -### Protection+## Protection  - **Panel supply** behind a 6.3 A fuse. - **Switched rail** delivered through a 10 A load switch, galvanically isolated from the controller that commands it.@@ -113,54 +137,29 @@ orientation of the panel on the base scaffold frame. - **USB data lines** ESD-protected.  🔶 **FILL-IN (Caleb):** published overcurrent/overvoltage trip and recovery thresholds per-rail, and any ingress rating. (Design targets for the USB eFuse exist in the Control Panel-Test Procedure, but those are test-acceptance values rather than published panel specs —-promote them here once confirmed.)--### Environmental--🔶 **FILL-IN (Caleb):** operating temperature and humidity range. Note the panel carries-environmental sensing, so the stated envelope should be reconciled with that sensor's range.+rail, and any ingress rating. -## Connector / Disconnect+## Environmental -The scaffold mates to the workcell through a **Samtec ET60 blade dock** — the connector that-makes and breaks on every docking cycle.--| Side | Part |-|---|---|-| **Workcell (system)** | Samtec **ET60S-S03** |-| **Scaffold (user)** | Samtec **ET60T-S03** |+The base scaffold and its control panel operate in a **controlled 20 – 25 °C** environment. -**Contact set** — three power blades plus a signal field:+On-board sensing spans a considerably wider envelope than the operating environment, so+sensor range is not the limiting factor: -| Blade | Rail |+| Measurement | Range | |---|---|-| P1 | PS1 — 0–60 V / 12 A |-| P2 | PS2 — 5 V / 10 A, switchable |-| P3 | PS3 — spare |--Each blade carries **five contacts per polarity, with separate returns**. The signal field-carries debug, MCU boot/reset control, spare control lines and low-voltage service rails.--> ⚠️ **To reconcile:** the scaffold design describes the dock as *3 power blades + 60 signal-> pins*, while the workcell design's summary says *3 blades + 25 signals*. These are most-> likely **60 physical positions vs. 25 currently assigned** — the two should be made to-> agree before this page is final. 🔶 **FILL-IN (Caleb).**--🔶 **FILL-IN (Caleb)** — not yet published, and important because this connector mates on-every docking cycle:--- **Rated mating cycles** and blind-mate / misalignment tolerance.-- **Connect/disconnect sequencing** — whether the dock is hot-pluggable or must be sequenced. The panel already has the means for a safe sequence, since PS2 is switchable and can be de-energized before extraction; confirm what is required of PS1/PS3, and whether the blade geometry provides first-make/last-break ordering.-- **Safety** — lockout/tagout, interlock with the workcell, and E-stop behavior across the connector.-- **Mechanical interaction** — whether a scaffold can physically slide out of a workcell while still electrically connected, and what prevents it if not.+| Temperature | −40 … +85 °C |+| Relative humidity | 0 … 100 % RH |+| Barometric pressure | 300 … 1100 hPa |+| Air quality | Gas-resistance based indoor air-quality sensing |+| Acceleration | ±2 / ±4 / ±8 / ±16 g selectable |+| Angular rate | ±125 … ±2000 °/s selectable |  ## Relationship to the Rest of the System -- The **electrical boundary** sits at the dock: everything upstream — bench inputs, metering, the workcell controller and the cell's own connectivity — is the workcell half. Everything the project touches — rails at the machine contacts, user I/O, USB and ground bonding — is the scaffold half.+- The **electrical boundary** sits at the dock: everything upstream — bench inputs, metering and the workcell controller — is the workcell half. Everything the project touches — rails at the machine contacts, user I/O, USB and ground bonding — is the scaffold half. - Wiring from the panels to the control panel is bent automatically; gauges and termination are documented in the [Base Scaffold System — Wiring](https://wiki.adom.inc/adom/base-scaffold-system) section (James/Luke).-- The project's connections land on the **65-contact machine field**, terminating exactly like every other contact on the scaffold.+- The project's connections terminate on the machine-contact field exactly like every other contact on the scaffold.  🔶 **FILL-IN (Caleb + James/Luke):** confirm which specs are authoritative here versus the Panels section of the main page — contact ratings in particular appear in both places.